Electrostatic Precipitator Electrical Operation &

Trouble shooting

M1

Presented by
E3
A.Charles Paniraj
ESP Standard Electrical Equipment

1.TRANSFORMER
2.TR CONTROL PANEL & INCOMER PANEL
3.PIACS CONTROLLER
4.HEATER (INSULATOR HEATER, SHAFT & HOPPER HEATER)
5.RAPPING GEAR MOTOR (COLLECTING, DISCHARGE, INLET & OUTLET)
6.RTD (INSULATOR, SHAFT & HOPPER HEATER)
7.THERMOSTAT
8.PURGE AIR FAN
9.TWIDO PLC WITH HMI
10.GROUNDING ROD AND CLAMP
11.EARTHING CABLE & LUGS
12.BRAIDED COPPER CABLE
13.HEATER JUNCTION BOX
14.LPBS / ISOLATOR BOX
15.ANYBUS GATEWAY
16.ANYBUS CONVERTER FOR PURGE AIR FAN
17.POWER MONITOR FOR PURGE AIR FAN
18.MECHANICAL KEY INTERLOCK
19.WARNING SIGN
20.FLS AIRTECH SIGN BOARD
21.MOTORIZED GROUND SWITCH
22. SUPPORT INSULATORS, SHAFT, LEAD-IN INSULATOR
23. PIN INSULATOR
24. GASKET
25. LEVEL SWITCH
26. ZSS
27. EMCS Board
28. HOIST MOTOR
29. DUST TRANSPORT MOTOR ( SCRAPPER, AIR SLUICE, DRAG CHAIN, SCREW
CONVEYOR)
Electrostatic Precipitator
Control system PIACS DC tasks
ESP Field

Control Panel
HV output Heating

E1 E2
PIACS DC
High voltage tank
M3

M2

Rappers

M1

Main E3
ESP Basic Theory
Electrostatic precipitation principle
 Block diagram of a TR set

Phase control HV tank

thyristors

Linear inductance HV transformer HV rectifier

ESP

AC line
Output
stage

Firing angle Shunt

kV-signal
mA-signal
Mean
current
PI controller Interface

Error
PIACS DC
Reference
Ref. signal generator
Electrostatic Precipitator
Control system PIACS DCTM
PIACS-DC is a microprocessor-based automatic control unit for DC-high voltage power supplies, rapping and
heating of electrostatic precipitators developed by F.L.Smidth Airtech

PIACS DC IDC 800 mA UDC 56.5 kV

Temp
7 8 9
ALARM LIMIT
RESET T CONFIG
T/R

O I STATUS
I 4 5 6 RAMP
T/R
Time
T/R unit
CORON
O I STATUS
U 1 2 3 A
T/R
POR

O I STATUS TUNING
T/R T/R T/R
MISC
0 T/R
EMCS
Electrostatic Precipitator
Control system PIACS DCTM

Temp
7 8 9
ALARM LIMIT
RESET T CONFIG
T/R

STATUS
I 4 5 6 RAMP
T/R
Time

STATUS CORON
U 1 2 3 A
T/R
POR

STATUS TUNING
T/R
MISC
0 T/R
EMCS
Electrostatic Precipitator
Control system PIACS DCTM

Temp
7 8 9
ALARM LIMIT
RESET T CONFIG
T/R

STATUS
I 4 5 6 RAMP
T/R
Time

STATUS CORON
U 1 2 3 A
T/R
POR

STATUS TUNING
T/R
MISC
0 T/R
EMCS
Electrostatic Precipitator
How to operate PIACS

Example to select LEVEL_2:

Switch on PIACS
By default the Level is 0

Press Then type 2220 from

Press
ALARM
RESET T 7 8 9 CONFIG
LIMIT
T/R
Temp

STATUS
I 4 5 6 RAMP
T/R
Time

STATUS CORON
U 1 2 3 A
T/R
POR

STATUS TUNING
T/R
MISC
0 T/R
EMCS
 Electrostatic Precipitator

Switch on PIACS
Enter password

Press Then type 3618 from

Press
ALARM
RESET T 7 8 9 CONFIG
LIMIT
T/R
Temp

STATUS
I 4 5 6 RAMP
T/R
Time

STATUS CORON
U 1 2 3 A
T/R
POR

•Then Enter the parameter values to0the controller, with the same procedure.
T/R
MISC
TUNING
T/R
EMCS

•For entering Parameter value refer A5 and A6 page.

•After entered the parameter values, Press key button then enter 53618 to save the parameter
values.
CONTROLLER PARAMETER
Refer A5 & A6 Pages in Electrical
Document
 CONTROLLER REFERENCE MANUAL

50221 - For Controller Opreation and Testing

50201 - For Trouble Shooting and Parameter details
50271 - For PIACS Controller Gate way communication.
7955951 - For Transformer
Single Line Diagram
Panel GA Drawing (4 no’s field panel and 1 incomer panel)
PANEL INTERNAL COMPONENET
PANEL FRONT VIEW
Distance Between Thyristor and Firing Angle board
Connecting Cable Less than 45cm
Electrostatic Precipitator
Firing Angle control board:

Temp
8 9
LIMIT
T CONFIG
T/R

STATUS
I

POR
Electrostatic Precipitator
PIACS internal view:

Temp
8 9
LIMIT
T CONFIG
T/R

STATUS
I

POR
A13 - HX03 Relay Board & Communication Cable
HV energization and control
Spark detection and voltage recovery
Spark detection principle
11: under voltage limit

12: time limit

Voltage recovery principle

13: mean voltage before spark

14: 1st level of voltage recovery

15: change from voltage to current control

16: voltage recovery time

17: reduced current level

Transformer (TR set)
 Transformer Instruments
Manual Ground Switch Pressure & Thermostat

Oil Level switch

 SIGNAL VOLTAGE FEEDBACK CARD
R5 Resistance – 1 ohm (Terminal X1: 1&2) mA Feedback
R7 Resistance – 10 K ohm (Terminal X1: 1&3)
R2 Resistance – Eg. 100kv = 100 meg ohm (Terminal VFB to HV
Bushing) use 1000Vdc meggar
Motorized Grounding Switch

Pin Insulator
Any bus Gateway module and LED healthy status
Twido PLC & HMI for Purge Air Fan

Twido PLC Purge Air Fan

HMI
PURGE AIR FAN WITH CALORIFIER UNIT
ROOF AND SIDE DRIVE RAPPING MOTOR
Rapping Hammers for discharge and collecting plates
RAPPING BAR
LPBS with NO & NC Blocks
LOCAL ISOLATOR SAFTY SWITCH
Support Insulators
Gap between collecting plate and discharge plate
Instrument Earthing and HV connection details
HV Connection with Braided copper cable

Door Earthing Grounding Clamp Machanical Safety lock

ESP Earthing system
ESP Main Grid Earthing
Hopper Level switch probe mounting
length – 1135 mm
(L1=400, L3=500, L2= 110+125mm)
Level Switch Relay and Probe Details
EMCS Board & Isolator Barrier
Mechanical Safety Key Interlock
Zero Speed Switch Probe & Control Unit

Sensing Probe Control Unit

 RTD (PT100 sensor)
Hopper Insulator

RTD connection
Discharge Drive RTD & Heater
 Grounding ROD and Clamp

Grounding Rod 1795mm Grounding Clamp 2000mm

Support Insulator with Heater and Lead-in Insulator
Support Insulator Heater & Terminals
 Support Bearing

Slide Bearing & Roller Bearing

Co gas Analyzer Equipment at ESP Inlet
Electrostatic Precipitator
TR SET- Control Wiring
 ALARM FOR TR SET

1. T/R INTERLOCKING
2. HIGH PRESSURE OIL TANK
3. HIGH TEMPERATURE OIL
TANK
4. LOW OIL LEVEL
5. T/R SET GROUNDED
6. MAINS OVER LOADED
7. T/R SET OPTIONAL ALARM
8. UNDER VOLTAGE 30Sec
9. OVER VOLTAGE 1 Sec
10.µP CHECK ERROR
11.MAINS SYNC. FAILURE
12.LOW TEMP E1 T/R INTERLOCK
13.TR CTRL. CMD. FAILURE
Electrostatic Precipitator
Rapping - PIACS DC
 ALARM FOR RAPPING MOTORS

1. RAP GROUP INTERLOCK ALARM

2. FEED-BACK FAILURE M1, M2, M3
3. MAINS FAILURE M1, M2, M3
4. SAFETY SWITCH OPEN M1, M2, M3
5. RAP CTRL. CMD. FAILURE
ALARM FOR HEATERS

1. HEAT GROUP INTERLOCK

2. FEED-BACK FAILURE E1 / E2 / E3
3. MAINS FAILURE E1/ E2 / E3
4. E1/ E2 / E3 PT 100 SENS. FAILURE
5. HEAT CTRL. CMD. FAILURE
6. E1 / E2 /E3 LOW TEMPERATURE WARN
Electrostatic Precipitator
Lamp load test (To check the function of SCRs):-

•Disconnect the T/R set power cable and connect serial

lamps (min 4X100W lamps).
•Check the jumper is fixed at rated frequency.
•Change the firing mode from auto to manual in the
AA30.1 board.
•Change the jumpers from CS28.5board (J5 &J6) to CU
19.1board (J5 &J6) for test mode.
•Turn on all the control breakers.
•Set the parameter 40 as 2 for TEST (manual) mode.
•Reset the T/R alarms if any.
•Switch on the MCCB and check the input voltage.
-Continued
Electrostatic Precipitator
•Switch on the MCCB and check the input voltage.
•Check the potentiometer R30 in AA30.1 board is fully
clockwise turned.
•Press the T/R on button to start the lamp load test and meas
voltage across lamp terminals (the minimum voltage).
•Then turn the potentiometer R30 to anti clockwise direction
during when the lamps will be increasing with brightness.
•When PotR30 turned fully to anti clockwise direction, check
voltage across the lamp terminals (the maximum voltage).
-Continued
Electrostatic Precipitator
•Reduce the output voltage by turning Pot R30 to fully
clockwise, then press T/R stop button to complete the
test.
•Auto Mode – Para #93 set 2 and Para #40 set 2
•Set Idc (limit TR) – set 100mA (min) and rated (rated
mA).

Sample reading:
Electrostatic Precipitator
Open circuit test (To check the T/R secondary voltage):-

•Connect and check the power, control cables for T/R set
both the ends.
•Keep the grounding switch of T/R set in HV position.
•Keep the secondary HV bush open (no wire/copper tube
connected).
•Power on the control breakers; check the parameters of
PIACS as per final approved drawing.
•Change the jumper in AA30.1 board in auto mode (firing
control).
•Power on the MCCB and press reset to clear the alarms
in PIACS. -Continued
Electrostatic Precipitator
•In PIACS set parameter 40 as 0 and parameter 47 as 170.
•Press T/R on button to start the test.
•Note down the value of Udc min, Udc max, Udc, Idc,
Primary current & spark rate from PIACS.
•Also check the (Primary) voltage across T/R out going
terminals.
•Then go to parameter 47 reduce the value from 170 to
160, take down readings as described.
•Repeat the same till the Udc max value reaches the rated
secondary voltage (peak).
•Press T/R off button to conclude test.
-Continued
Electrostatic Precipitator
Sample reading:
Electrostatic Precipitator

Short circuit test (To check the T/R secondary current):-

•Connect and check the power, control cables for T/R set
both the ends.
•Keep the grounding switch of T/R set in HV position.
•Connect the output of T/R set to ground with wire/field
discharging clamp.
•Power on the control breakers; check the parameters of
PIACS as per final approved drawing.
•Change the jumper in AA30.1 board in auto mode (firing
control). -Continued
Electrostatic Precipitator
•Power on the MCCB and press reset to clear the alarms
in PIACS.
•In PIACS set parameter 40 as 2, parameter 47 as 45 and
Idc limit to 10 mA.
•Press T/R on button to start the test.
•Note down the value of Udc, Idc, Primary current, I
density, firing angle & spark rate from PIACS.
•Also check the (Primary) voltage across T/R out going
terminals.
•Then increase the Idc limit, take down readings as
described.
•Repeat the same till the Idc value reaches the rated
secondary current. -Continued
Electrostatic Precipitator
•Press T/R off button to conclude test.

Sample reading:
Electrostatic Precipitator
Field meggering (To check short circuit between
electrodes):-
•Turn on support insulator heaters and keep temperature
above 70 deg C.
•Remove HV connection from T/R set in the support
insulator.
•Set the voltage of megger as 5000 volts; connect its
terminals across support insulator and ground.
•Ensure no men working inside ESP then press start
button in megger.
•Keep it on for 60 seconds and value should not be zero.
•If the IR value is low then check the internals again.
Electrostatic Precipitator
Field Charging (No load test):-

•Keep the grounding switch of T/R set in HV position.

•Connect the output of T/R set to field with wire/copper
tubes.
•Ensure no men working inside and all inspection doors
locked with chain.
•Check the Earth resistance of grid which should be less
than an ohm.
•Power on the control breakers; check the parameters of
PIACS as per final approved drawing.
•Change the jumper in AA30.1 board in auto mode.
-Continued
Electrostatic Precipitator
•Power on the MCCB and press reset to clear the alarms
in PIACS.
•In PIACS set parameter 40 as 0, parameter 47 as 45 and
Idc limit to 10 mA.
•Press T/R on button when support insulator temperature
is above 70 deg C to start the test.
•Note down the value of Udc min, Udc max, Udc, Idc,
Primary current, I density, firing angle & spark rate from
PIACS.
•Also check the (Primary) voltage across T/R out going
terminals.
•Then increase the Idc limit, take down readings.
-Continued
Electrostatic Precipitator
•Repeat the same till the Idc value reaches the rated
secondary current.
•Press T/R off button to conclude test.

Sample reading:
Electrostatic Precipitator
Air Load Test:
•Start the ID fan and run it at a speed to maintain 60%
(min) air flow inside ESP.
•Then charge the ESP as described in No load test.
•Take down the readings as required.

Sample Reading:
Electrostatic Precipitator
Gas Load Test:
•Change the jumpers from CU 19.1board (J5 &J6) to
CS28.5board (J5 &J6).
•Charge the ESP when the flue gas temperature value is
25⁰C above than the acid dew point temperature (in
general it will be safe when gas temp is 100 + 20⁰C).
•Take down the readings and plot the Current Voltage
curve for each field.
•Check the dust conveying system operation, Spark rate,
Rapping sequence and heaters temperature frequently.
•Also check for Back corona when you have dust
emission during running condition of ESP.
Electrostatic Precipitator
Normal CVC curve - Sample:
Electrostatic Precipitator
Back corona CVC curve - Sample:
 T/R SET starting & RUNNING Interlocks

Insulator Heater temperature should be minimum 70 deg C.

Inlet gas temperature must be follow as per operation manual for start up (min 170 deg).
ESP hopper level should not be high.
ID fan running feedback.
Rapping Group & Heater group running feedback.
Inlet temperature reaches 400 deg C , ID Fan should be tripped.
RAV running feedback.
Dust transportation system running feed back.
Electrostatic Precipitator, Type C / E - PIACS DC
Operation
Start sequence Stop sequence

Startheating
heatingelements
elements Startthe
Start thestop
stopsequence
sequence
Start
1) 6-12hours
hoursininadvance
advance forthe
thededusted
dedustedapplication
application
6-12 for

When temperature ok When temperature pass minimum

Dusttransport
Dust transportinin Switchoff
offthe
thehigh
highvoltage
voltage
2) Switch
operationincl.
operation incl.rapping
rapping
Minimum 3 hours
Bottom hopper empty
Startgas
Start gasflow
flowthrough
through Switchoff
Switch offthe
thedust
dusttransport
transport
3) theESP
ESP inclrapping
rapping
the incl
When temperature and
Stop for more than 24 hours
operation ok

4)
Switchon
Switch onthe
thehigh
highvoltage
voltage Stopheating
Stop heatingelements
elements

This is headlines from the operation manual

Electrostatic Precipitator

Tools required for Testing:

•Multimeter
•Clamp meter
•1000V DC Megger for Transformer testing
•5000V DC Megger for Field testing
•Spanner set
•Screw driver set
•Laptop, communication cables with softwares.
Electrostatic Precipitator

Preliminary check:

•Supplied voltage.
•Parameter settings.
•Earthing.
•Device name plate checking.
•Mounting of equipments.
•Cable glands and terminations.

-Continued
Electrostatic Precipitator

•Insulation resistance of device with cable.

•Breaker current ratings and tripping values.
•Direction of rotation for motors.
•Heater operation.
•RTD connection and resistance.

Checking of internals in ESP:

•Impact point of rapping hammers.

•Distance between plates and electrodes.
•Earthing of all inspection doors.
•Housekeeping of internals to remove unwanted
materials.
Electrostatic Precipitator

Commissioning sequence:

•Lamp load test.

•Trial run of rapping motors from LPBS & controller.
•Trial run of heaters.
•T/R set open circuit test.
•T/R set short circuit test.
•Field meggering for short circuits.
•No load test.
•Air load test.
•Gas load test.
QUERIES

THANK YOU